Systems and methods for advanced closed loop control and improvement of combustion system operation

ABSTRACT

A system includes an analytics system including a processor configured to receive an indication of a detectable radiation associated with a combustion system. The detectable radiation includes multidimensional granular data associated with an operation of the combustion system. The processor is configured to determine a first value of one or more operational characteristics of the combustion system based at least in part on the indication of the detectable radiation, and to derive an output. The output includes a second value derived based on the first value of the one or more operational characteristics to adjust the first value thereto.

BACKGROUND

The invention relates generally to combustion systems, and more specifically to systems and methods for improved and advanced control of combustion systems.

Combustion systems within gas turbine systems, boiler systems (e.g., coal fired boiler systems), or other similar systems may include a number of sensors to measure and/or detect the various operating parameters of the combustion systems, and by extension, the operating parameters of the systems (e.g., gas turbine systems, boiler systems, and so forth) including the combustion systems. However, these sensors may be limited in detecting certain data of the combustion systems. Moreover, the data detected by more advanced sensors may require more advanced data converters and/or data processors. It may be useful to provide systems to improve data detection and control of combustion systems.

BRIEF DESCRIPTION

Certain embodiments commensurate in scope with the originally claimed invention are summarized below. These embodiments are not intended to limit the scope of the claimed invention, but rather these embodiments are intended only to provide a brief summary of possible forms of the invention. Indeed, the invention may encompass a variety of forms that may be similar to or different from the embodiments set forth below.

A system includes an analytics system including a processor configured to receive an indication of a detectable radiation associated with a combustion system. The detectable radiation includes multidimensional granular data associated with an operation of the combustion system. The processor is configured to determine a first value of one or more operational characteristics of the combustion system based at least in part on the indication of the detectable radiation, and to derive an output. The output includes a second value derived based on the first value of the one or more operational characteristics to adjust the first value thereto.

A non-transitory computer-readable medium having code stored thereon, the code includes instructions to receive an indication of a detectable radiation associated with a combustion system. The detectable radiation includes multidimensional granular data associated with an operation of the combustion system. The code includes instructions to determine a first value of one or more operational characteristics of the combustion system based at least in part on the indication of the detectable radiation, and to derive an output. The output includes a second value derived based on the first value of the one or more operational characteristics to adjust the first value thereto.

A system includes a plurality of sensors configured to detect electromagnetic radiation associated with a combustor of a turbine system, and a data analytics system configured to receive an indication of the electromagnetic radiation. The indication of the electromagnetic radiation includes multidimensional granular data associated with an operation of the combustor. The data analytics system is configured to determine a first value of one or more operational characteristics of the combustor based at least in part on the indication of the electromagnetic radiation, and to derive an output. The output includes a second value derived based on the first value of the one or more operational characteristics to adjust the first value thereto. The system includes a controller configured to receive the output and to generate a control command based at least in part on the output.

DRAWINGS

These and other features, aspects, and advantages of the present invention will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings, wherein:

FIG. 1 is a block diagram of an embodiment of a gas turbine system including a combustion system, in accordance with present embodiments;

FIG. 2 is a diagram of an embodiment of the system of FIG. 1, including an analytics system, in accordance with present embodiments; and

FIG. 3 is a flowchart illustrating an embodiment of a process useful in providing improved control of operational parameters of the combustion system of FIG. 1, in accordance with present embodiments.

DETAILED DESCRIPTION

One or more specific embodiments of the invention will be described below. In an effort to provide a concise description of these embodiments, all features of an actual implementation may not be described in the specification. It should be appreciated that in the development of any such actual implementation, as in any engineering or design project, numerous implementation-specific decisions must be made to achieve the developers' specific goals, such as compliance with system-related and business-related constraints, which may vary from one implementation to another. Moreover, it should be appreciated that such a development effort might be complex and time consuming, but would nevertheless be a routine undertaking of design, fabrication, and manufacture for those of ordinary skill having the benefit of this disclosure.

When introducing elements of various embodiments of the invention, the articles “a,” “an,” “the,” and “said” are intended to mean that there are one or more of the elements. The terms “comprising,” “including,” and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements.

Present embodiments relate to systems and methods useful in providing improved control of combustion systems (e.g., combustions systems in gas turbine systems) in real-time. Specifically, one or more electromagnetic detectors (e.g., optical detectors, transducers, spectrometers, and so forth) in conjunction with an analytics system may be provided as part of a closed-loop control system. The electromagnetic detectors in conjunction with the analytics system may allow for improved control of gas turbine and/or combustion system operational parameters of interest such as the combustion dynamics (e.g., pressure, flame intensity), heat rate, gas emission dynamics, maintenance factor, and so forth to improve the operational characteristics of the gas turbine and/or combustion system. The electromagnetic detectors in conjunction with the analytics system may also provide for better prognostics and diagnostics of the gas turbine and/or combustion systems that may be otherwise unavailable using only observational devices such as infrared cameras. Although discussed primarily in relation to a gas turbine system, it should be appreciated that the present embodiments may be applicable to any system including combustion systems and/or burner systems such as coal-fired boiler systems or other similar systems.

With the foregoing in mind, it may be useful to describe an embodiment of a gas turbine system, such as an example gas turbine system 10 illustrated in FIG. 1. In certain embodiments, the gas turbine system 10 may include a gas turbine 12, a control system 14, and a fuel supply system 16. As illustrated, the gas turbine 12 may include a compressor 20, combustion chambers 22, fuel nozzles 24, a turbine 26, and an exhaust section 28. During operation, the gas turbine 12 may take in air 30 into the compressor 20. The compressor 20 may then compress and move the air 30 to the combustion chambers 22 (e.g., chambers including a number of combustors or burners).

In certain embodiments, the combustion chambers 22, using the fuel nozzles 24, may take in fuel 31 that mixes with the now compressed air 30 creating an air-fuel mixture. The air-fuel mixture may combust within the combustion chambers 22 to generate hot combustion gases, which flow downstream into the turbine 26 to drive the turbine 26. For example, the combustion gases may move through the turbine 26 to drive one or more stages of blades of the turbine 26, which may in turn drive rotation of a shaft 32. The shaft 32 may connect to a load 34, which may include, for example, a generator to convert the output of the shaft 32 into electric power. In certain embodiments, upon passing through the turbine 26, the hot combustion gases may vent into the environment as exhaust gases 36 via the exhaust section 28. The exhaust gas 36 may include major species such as, for example, carbon dioxide (CO₂), nitrogen (N₂), water vapor (H₂O), and oxygen (O₂), as well as minor species (e.g., pollutants) such as, for example, carbon monoxide (CO), nitrogen oxides (NO_(x)), unburned hydrocarbons (UHC), and sulfur oxides (SO_(x)).

In certain embodiments, the control system 14 may include a controller 38 communicatively coupled to an analytics system 40, and a number of sensors 42. The analytics system 40 may receive data relating to one or more components of the gas turbine system 12 from the sensors 42, and generate and transmit outputs to the controller 38 based on an analysis of the sensor 42 data. For example, as will be further appreciated, the analytics system 40 may use the sensor 42 data to determine, for example, CO₂ levels in the exhaust gas 36, pollutant (e.g., CO, NO_(x), UHC, SO_(x)) levels in the exhaust gas 36, carbon content in the fuel 31, temperature of the fuel 31, temperature, pressure, clearance (e.g., distance between stationary and rotating components), flame temperature or intensity, vibration, combustion dynamics (e.g., fluctuations in pressure, flame intensity, and so forth), and load data from load 34.

Turning now to FIG. 2, which illustrates an embodiment of the control system 14. In certain embodiments, the sensors 42 may include any of a number of electromagnetic radiation detectors (e.g., antennas, transducers, spectrometers, optical detectors, and so forth) that may be used to detect radiation 43 (e.g., flame and/or light radiation, intensity, and so forth) of the combustion chambers 22 and/or the fuel nozzles 24 and individual combustors (e.g., can combustors, burners) of the combustion chambers 22. For example, in certain embodiments, the sensors 42 may include photodetectors (e.g., colorimeters, flame sensors, wavefront sensors, photodiodes, infra-red sensors, and so forth), antennas (e.g., single-element, linear array, phased array), acoustic transducers (e.g., ultrasonic transducers), or any such devices useful in detecting the radiation 43. Thus, the sensors 42 may be useful in sensing the radiation 43 across various frequency ranges (e.g., across the electromagnetic spectrum) including, for example, frequencies within the x-ray, ultraviolet, visible, infrared, microwave, radio frequency (RF), gamma, millimeter wave ranges, and the like.

As further illustrated in FIG. 2, in certain embodiments, the radiation 43 detected by the sensors 42 may be transmitted to the analytics system 40, in which certain operational characteristics and/or parameters may be determined by the analytics system 40 based on the output of the sensors 42. For example, based on the output of the sensors 42, the analytics system 40 may derive chemical composition of gases of the exhaust gas 36, wear patterns inside of the combustion chambers 22, thermal distribution, physical geometry, pollutant levels in the exhaust gas 36, carbon content in the fuel 31, temperature of the fuel 31, temperature, pressure, flame temperature, vibration, combustion dynamics such as fluctuations in pressure, flame intensity, and so forth, of the combustion chambers 22 and/or the exhaust section 28. Specifically, by including the sensors 42 to detect the radiation 43, the sensors 42 may provide multidimensional granular data (e.g., three-dimensional data) of the combustion chambers 22 to the analytics system 40. Specifically, while certain non-electromagnetic sensors may provide a bulk average of data and other associated operational properties, the sensors 42 may provide granular data to, for example, the analytics system 40. The analytics system 40 may parse and delineate various regions of a field of the granular data (e.g., specific data of interest extracted from a larger portion of data). In this manner, the analytics system 40 may generate an output to the controller 38 to control one or more operational parameters of particular interest. For example, should one burner (e.g., can combustor) of the combustion chambers 22 burn much hotter than other burners of the combustion chambers 22, the analytics system 40 may identify the problematic burner before the burner is allowed to adversely impact the operation of the gas turbine system 12. Such multidimensional granular data may be otherwise undetectable when using less optimal devices such as infrared cameras or other similar devices (e.g., devices incapable of measuring the radiation 43).

Indeed, the analytics system 40 may be any hardware system, or a combination of a hardware and software system, suitable for analyzing, deriving, and/or modeling combustion data, exhaust emissions data, and/or other data relating to the combustion chambers 22 of the gas turbine 12. As illustrated, the analytics system 40 may include one or more processors 44, a memory 46 (e.g., storage), input/output (I/O) ports (e.g., one or more network interfaces 48), and so forth, useful in implementing the techniques described herein. Particularly, the analytics system 40 may include code or instructions stored in a non-transitory machine-readable medium (e.g., the memory 46 and/or storage) and executed, for example, by the one or more processors 44 that may be included in the analytics system 40. Additionally, the analytics system 40 may include a network interface 48, which may allow communication between the analytics system 40 and the controller 38 and sensors 42 via a personal area network (PAN), a local area network (LAN) (e.g., Wi-Fi), a wide area network (WAN), a physical connection (e.g., an Ethernet connection), and/or the like.

In certain embodiments, the analytics system 40 may receive and/or derive granular three-dimensional (3-D) data (e.g., combustion data, exhaust emissions data, or other data relating to non-homogenous phenomena) based on the inputs received from the sensors 42. For example, as previously noted, the analytics system 40 may used the data collected by the sensors 42 to derive certain composition of gases of the exhaust gas 36, wear patterns inside of the combustion chambers 22, thermal distribution of the flame of the combustion chambers 22, inner geometry of the individual combustors (e.g., individual can combustors), pollutant levels in the exhaust gas 36, carbon content in the fuel 31, temperature of the fuel 31, flame temperature, combustion dynamics such as fluctuations in pressure, flame intensity, and so forth.

Thus, in certain embodiments, the analytics system 40 may use Fourier analysis (e.g., Fast Fourier Transforms [FFTs], spectral analysis), image recognition techniques (e.g., pattern and gradient matching, optical character recognition), digital filtering techniques (e.g., Kalman filtering and/or other adaptive filtering), and similar signal processing techniques to extract and/or derive real-time or near real-time data from the input signals of the sensors 42 relating to the operation of the combustion chambers 22, and by extension, the operation of the gas turbine 12. Specifically, the analytics system 40 may perform various spectral analyses of the frequency components (e.g., frequency harmonics, power, frequency and/or signal distortion, and similar spectral components) to derive certain operational characteristics and/or parameters of the combustion chambers 22 and/or the gas turbine system 12. For example, in one embodiment, based on the inputs received via the sensors 42, the analytics system 40 may provide for improved detection and analysis of pollutant (e.g., CO, NO_(x), UHC, SO_(x)) levels in the flame of the combustion chambers 22 and/or exhaust section 28, which, if left to persist, may result in undesirable variations in exhaust section 28 temperature, the power output of the gas turbine 12, as well as the heat rate of the gas turbine 12. Specifically, by the analytics system 40 deriving the pollutant (e.g., CO, NO_(x), UHC, SO_(x)) levels in the flame of the combustion chambers 22, certain operating conditions such as, for example, lean blowouts (LBOs) (e.g., loss of flame due to a decrease in air-fuel ratio) in one or more individual combustors (e.g., can combustors) of the combustion chambers 22 may be detected with a higher degree a certainty.

Similarly, in other embodiments, the analytics system 40 may use probabilistic techniques, such as statistical methods (e.g., linear regression, non-linear regression, ridge regression, data mining) and/or artificial intelligence models (e.g., expert systems, fuzzy logic, support vector machines [SVMs], logic reasoning systems) to improve certainty in prognosis and/or diagnostics of the operating conditions of the combustion chambers 22, and by extension, the gas turbine 12. For example, certain knowledge of the gas turbine system 12 exhaust section 28 plane emissions may be analyzed to detect conditions possibly leading to an LBO, such as detecting that an outlying combustor of the combustion chambers 22 is not synchronized with other combustors of the combustion chambers 22.

As further illustrated in FIG. 2, in certain embodiments, the analytics system 40 may derive one or more outputs (e.g., in real-time or near real-time) based upon the operational characteristics and/or parameters derived from the data received via the sensors 42. The one or more outputs may include, for example, data values (e.g., target values, setpoint values) to vary (e.g., in real-time or near real-time) the operational characteristics of the combustion chambers 22 derived by the analytics system 40. In some embodiments, the analytics system 40 may derive an output to correct any of a number of non-homogeneous phenomena (e.g., fluctuations in pressure and flame intensity, heat rate, pollutant levels in the flame, thermal radiation, and so forth) associated with the combustion chambers 22. The analytics system 40 may transmit the one or more outputs to the controller 38 to execute one or more control actions. For example, the controller 38 may output a control signal to control one or more control elements 50 (e.g., actuators, valves, trim valves) to execute a control action to alter operating parameters including, for example, compressor 20 inlet airflow, compressor 20 exit airflow, flow of fuel 31 to the combustion chambers 22, and so forth, to adjust and stabilize the flame output of the combustion chambers 22, and by extension, the power output of the gas turbine 12.

Turning now to FIG. 3, a flow diagram is presented, illustrating an embodiment of a process 52 useful in providing improved control of combustion systems in real-time, by using, for example, the analytics system 40 in conjunction with the controller 38 included in the gas turbine system 10 depicted in FIG. 1. The process 52 may include code or instructions stored in a non-transitory computer-readable medium (e.g., the memory 46) and executed, for example, by the one or more processors 44 included in the analytics system 40 and/or processors included within the controller 38. The process 52 may begin with the analytics system 40 receiving (block 54) system operating parameters of the gas turbine 12. As previously discussed, the analytics system 40 may receive one or more indications of the operating parameters of the combustion chambers 22 detected via the sensors 42 (e.g., electromagnetic radiation detectors). For example, as previously discussed, the sensors 42 may detect the radiation 43 (e.g., electromagnetic radiation) emitted, for example, by the flame of the combustion chambers 22.

The process 52 may then continue with the analytics system 40 analyzing (block 56) and/or deriving from, the system operating parameters for specific parameters of interest. For example, as noted above with respect to FIG. 2, the analytics system 40 may derive from the radiation 43 detected by the sensors 42 operational characteristics and/or parameters including, for example, CO₂ levels in the exhaust gas 36, pollutant (e.g., CO, NO_(x), UHC, SO_(x)) levels in the flame of the combustion chambers 22 and/or exhaust gas 36, carbon content in the fuel 31, temperature of the fuel 31, certain combustion dynamics (e.g., fluctuations in pressure, flame intensity) of the combustion chamber 22, heat rate of the gas turbine 12, maintenance factor (e.g., maintenance intervals) of the gas turbine 12, and so forth. The analytics system 40 may then calculate (block 58) one or more outputs based on the analysis and/or derivation of the specific operating parameters of interest. Specifically, the analytics system 40 may calculate one or more target data values and/or setpoint values for the specific operating parameters of interest to be adjusted thereto. That is, the analytics system 40 may parse and delineate various regions of a field of data and derive an output to correct any of number non-homogeneous phenomena associated with the combustion chambers 22 with a high degree of specificity. In this manner, the analytics system 40 may generate an output derived and/or characterized to reflect one or more operational parameters of particular interest based on the data received via the sensors 42. As previously noted, such techniques may not be possible when using less optimal devices such as infrared cameras, less advanced controllers, or other similar devices (e.g., devices incapable of measuring and processing the radiation 43).

The calculated one or more outputs may be then used by the controller 38 to generate (block 59) and execute one or more corresponding control commands. Indeed, the one or more calculated outputs may be used by the controller 38 to adjust (block 60) one or more control elements (e.g., final control elements such as actuators, valves, and the like) coupled to the combustion chambers 22 or other components of the gas turbine 12. For example, one or more actuator and/or control valve signals may be generated by the controller 38 to control, for example, the fuel flow to the combustion chambers 22, and by extension, the fuel (e.g., fuel 31) flow to the gas turbine system 12.

Technical effects of the present embodiments include systems and methods useful in providing improved control of combustion systems (e.g., combustions systems in gas turbine systems) in real-time. Specifically, one or more electromagnetic detectors (e.g., optical detectors, transducers, spectrometers, and so forth) in conjunction with an analytics system may be provided as part of a closed-loop control system. The electromagnetic detectors in conjunction with the analytics system may allow for improved control of gas turbine and/or combustion system operational parameters of interest such as the combustion dynamics (e.g., pressure, flame intensity), heat rate, gas emission dynamics, maintenance factor, and so forth to improve the operational characteristics of the gas turbine and/or combustion system. The electromagnetic detectors in conjunction with the analytics system may also provide for better prognostics and diagnostics of the gas turbine and/or combustion systems that may be otherwise unavailable using only observational devices such as infrared cameras.

This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal language of the claims. 

1. A system, comprising: an analytics system, comprising: a processor configured to: receive an indication of a detectable radiation associated with a combustion system, wherein the detectable radiation comprises multidimensional granular data associated with an operation of the combustion system; determine a first value of one or more operational characteristics of the combustion system based at least in part on the indication of the detectable radiation; and derive an output, wherein the output comprises a second value derived based on the first value of the one or more operational characteristics to adjust the first value thereto.
 2. The system of claim 1, comprising a sensor configured to detect the radiation and to transmit the indication of the radiation to the processor.
 3. The system of claim 2, wherein the sensor comprises an electromagnetic radiation detector.
 4. The system of claim 2, wherein the sensor is configured to detect the radiation within an x-ray frequency range, an ultraviolet frequency range, a visible light frequency range, an infrared frequency range, a gamma frequency range, a microwave frequency range, a radio frequency (RF) frequency range, a millimeter wave frequency range, or any combination thereof.
 5. The system of claim 1, wherein the processor is configured to determine the first value of the one or more operational characteristics of the combustion system by analyzing a plurality of frequency components of the indication of the detectable radiation.
 6. The system of claim 1, wherein the processor is configured to derive the output when the first value is above or below a configurable threshold value.
 7. The system of claim 1, wherein the processor is configured to: utilize a spectral analysis technique to analyze frequency components of the indication of the detectable radiation, wherein the frequency components comprise indications of an intensity of a flame of the combustion system as the first value; and derive the output as a fuel flow value as the second value.
 8. The system of claim 1, wherein the combustion system is configured to couple to a gas turbine system, a boiler system, or a combination thereof.
 9. The system of claim 1, comprising a controller configured to receive the output and to execute a control action for controlling at least one component coupled to the combustion system based on the output.
 10. The system of claim 9, wherein the controller is configured to execute the control action comprising actuating an actuator, and wherein the actuator is configured to control a flow of fuel into the combustion system.
 11. A non-transitory computer-readable medium having computer executable code stored thereon, the code comprising instructions to: receive an indication of a detectable radiation associated with a combustion system, wherein the detectable radiation comprises multidimensional granular data associated with an operation of the combustion system; determine a first value of one or more operational characteristics of the combustion system based at least in part on the indication of the detectable radiation; and derive an output, wherein the output comprises a second value derived based on the first value of the one or more operational characteristics to adjust the first value thereto.
 12. The non-transitory computer-readable medium of claim 11, wherein the code comprises instructions to receive the indication of the detectable radiation within an x-ray frequency range, an ultraviolet frequency range, a visible light frequency range, an infrared frequency range, a gamma frequency range, a microwave frequency range, a radio frequency (RF) frequency range, a millimeter wave frequency range, or any combination thereof.
 13. The non-transitory computer-readable medium of claim 11, wherein the code comprises instructions to determine the first value of the one or more operational characteristics of the combustion system by analyzing a plurality of frequency components of the indication of the detectable radiation.
 14. The non-transitory computer-readable medium of claim 11, wherein the code comprises instructions to derive the output when the first value is above or below a configurable threshold value.
 15. The non-transitory computer-readable medium of claim 11, wherein the code comprises instructions to: utilize a spectral analysis technique to analyze frequency components of the indication of the detectable radiation, wherein the frequency components comprise indications of an intensity of a flame of the combustion system as the first value; and derive the output as a fuel flow value as the second value.
 16. The non-transitory computer-readable medium of claim 11, wherein the code comprises instructions to transmit the output to a controller.
 17. The non-transitory computer-readable medium of claim 16, wherein the code comprises instructions to instruct the controller to execute a control action for controlling at least one component coupled to the combustion system.
 18. A system, comprising: a plurality of sensors configured to detect electromagnetic radiation associated with a combustor of a turbine system; a data analytics system configured to: receive an indication of the electromagnetic radiation, wherein the indication of the electromagnetic radiation comprises multidimensional granular data associated with an operation of the combustor; determine a first value of one or more operational characteristics of the combustor based at least in part on the indication of the electromagnetic radiation; and derive an output, wherein the output comprises a second value derived based on the first value of the one or more operational characteristics to adjust the first value thereto; and a controller configured to receive the output and to generate a control command based at least in part on the output.
 19. The system of claim 18, wherein the plurality of sensors comprises a plurality of optical detectors configured to detect electromagnetic radiation associated with a flame of the combustor.
 20. The system of claim 18, wherein the controller is configured to generate the control command to adjust an inlet airflow, an exit airflow, an exit pressure, an inlet fuel flow, or a combination thereof, of the turbine system. 